Cost-Efficient and Sustainable Solutions With Duplex Nov 2012

Cost-efficient and Sustainable

Solutions with Duplex

Outokumpu Customer Seminar, Middle East, November 2012

www.outokumpu.com

2 November 2012 2

Do you know your maintenance cost?

1000 m2

Actual coating cost?

Maintenance repair of coatings?

Lost production during maintenance?

Safety issues?

Environmental issues?

Short service life?

Wouldn't be better to

eliminate the coating…

Duplex!

2 November 2012 3

Contents

1. The Duplex business case

2. Cost-efficient tank design

3. Case: Cost analysis of storage tank shell

4. Successful tank solutions in Duplex

5. Conclusions: Sustainable tank solutions in Duplex

2 November 2012 3

80 years of Duplex experience

Outokumpu is the leader of

duplex innovations:

• Avesta Steelworks in Sweden

produced the first commercial

duplex grades starting around

1930

• In more recent years the

pioneer of lean duplex

grades…

The LDX™ family!

2 November 2012 4

Autoclave in duplex 453S

for production of gunpowder.

Delivered in 1933.

Positioning of Duplex grades

An excellent combination of high strength and corrosion resistance

2 November 2012 5

600

550

500

450

400

350

300

250

200

150

Du

ple

x

Au

ste

nti

c

4307

(304L)

4404

(316L)

4436

4438

(317L)

4439

904L

254 SMO®

4565

LDX 2101®

2304

2205

2507

LDX 2404®

Corrosion Resistance, CPT typical [C]

Str

en

gth

, R

p0.2

[M

Pa

]

Hot coil

Chemical composition and properties

2 November 2012 6

Steel grade Typical chemical composition,% PRE* Rp0.2min, RT**

Outokumpu EN ASTM Cr Ni Mo N Others MPa

Duplex stainless steels

LDX 2101® 1.4162 S32101 21.5 1.5 0.3 0.22 5Mn 26 450

LDX 2404® 1.4662*** S82441 24 3.6 1.6 0.27 3Mn 34 480***

2304 1.4362 S32304 23 4.8 0.3 0.10 - 26 400

2205 1.4462 S32205 22 5.7 3.1 0.17 - 35 460

2507 1.4410 S32750 25 7 4 0.27 - 43 530

Austenitic stainless steels

4307 1.4307 304L 18.1 8.1 - - - 18 200

4404 1.4404 316L 17.2 10.1 2.1 - - 24 220

904L 1.4539 904L 20 25 4.3 - 1.5Cu 34 220

254 SMO® 1.4547 S31254 20 18 6.1 0.20 Cu 43 300

* Pitting resistance equivalent, PRE = %Cr + 3.3x%Mo + 16x%N ** Values in accordance with EN 10088 for hot rolled plate.

*** 1.4662 is not yet included in EN 10088. Rp0.2 min. value according to ASTM A240 for t >10 mm.

Characteristics of the Duplex grades

2 November 2012 7

• Higher mechanical strength than standard grades

• Good resistance to pitting and crevice corrosion

• Good weldability

• Higher fatigue resistance than standard grades

• High resistance to stress corrosion cracking and

corrosion fatigue

• Low price for pitting and crevice corrosion resistance

(price for PRE very low)

• High wear resistance

• Low thermal expansion

• High energy absorption

Duplex =

Austenitic-ferritic structure

The Duplex business case

2 November 2012 8

Improved Cost Efficiency!

Opportunity

Benefits

Excellent mechanical properties

High corrosion resistance

Good fabricability

Characteristics

Thinner gauges due to higher strength –

Weight savings!

Better durability and reduced maintenance –

Longer service life!

Cost efficient alloying (High N, low Ni) –

Cost stability!

Customer service and prefabrication –

Support and added value!

Brings multiple

sustainability

benefits!

Cost efficiency

2 November 2012 9

Cost Efficiency = Maximum Performance of the Investment

• Minimize Total Material Cost

• Minimize Total Fabrication Cost

• Minimize Total Life Cycle Cost

Total Life Cycle Cost

Material Cost

Total Initial Cost

Fabrication Cost

Operation and

Maintenance Cost

Total Life Cycle Cost

Material

Cost

Total Initial Cost

Fabrication

Cost

Operating

and

Maintenance

Cost

Successful solutions in Duplex

2 November 2012 10

The high corrosion

resistance and strength of

LDX 2404® mean it can be

used as a complement or

substitute in applications

where austenitic molother

duplex grades such as 2205

have traditionally been used.

Superior cost efficient solutions

for high strength constructions

in corrosive environments Courtesy of Kvaerner

Pressure vessels Storage tanks Desalination – Evaporators

Flexible lines

Roofing and wall panels Bridges Chemical tankers

Superior Cost Efficiency

for constructions in corrosive

environments

2 November 2012 11

Contents






Cost-efficient design – Utilize strength!

2 November 2012 12

Factors influencing how the strength can be utilized:

• Function: cylinder with internal pressure, plate in bending etc.

• Constraints:

• Shape (diameter, height etc.)

• Loading condition (wind loads, seismic loads, fatigue loads etc.)

• Material standards and design codes (allowable design stresses etc.)

7.8 200 655 450 2205

7.9 200 485 170 4307 (304L)

7.8 200 650 450 LDX 2101®

[x103kg/m3]

E [GPa]

Rm [MPa] Rp0.2 [MPa] Grade

Mechanical and physical properties, RT, minimum values

170 485 200 8.0 4404 (316L)

*Hot rolled plate at ambient temperature according to ASTM A 240

Utilize strength – Structural efficiency

2 November 2012 13

Pinternal >> Pexternal

Tank - base

⇒

Critical design criteria

Rp0.2

Pexternal >> Pinternal

Tank - top

⇒ E

Structural stability!

Structural instability!

P=Pressure

Utilize strength – Structural efficiency

2 November 2012 14

Critical design criteria

⇒ LDX 2101®/2205

~58

304L/316L

~21

Weight saving potential more than 50%

⇒ LDX 2101®/2205

~26 304L/316L

~25

Weight saving potential less than 3%

Rp0.2

E

2 November 2012 15

0

100

200

300

400

500

600

Proof strength, Rp0,2

API 650* EN 14015** EN 13445** ASME VIII-1****

LDX 2404™ LDX 2101® 2205 2304 4404 (316L)

Design strength at RT (MPa)

Storage tank codes Pressure vessel codes

*

®

* Design stresses in accordance with API 650, Appendix X (Duplex stainless steel), which refers further to ASTM A240.

** Design stresses in accordance with EN 14015, which refers further to EN 10088-2. Maximum design stress is limited to 260

MPa.

*** Design stresses in accordance with EN 13445, which refers further to EN 10028-7 (EAM or PMA if not included in EN 10028-7).

**** Design stresses in accordance with ASME VIII-1, which refers to ASME II-D, code cases, and ASME SA-240.

Note: LDX 2101 and LDX 2404 are pending for inclusion in EN 10088-2. They are not yet included in EN 10028-7 (EAM-0045-01

is applicable for LDX 2101, thicknesses up to and including 10 mm). ASME code case 2418-1 is applicable for LDX 2101.

ASME code case is pending for LDX 2404. LDX 2404 is not yet included in API 650 Appendix X.

Allowable design strength

Size matters – Tank shell design

2 November 2012 16

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

Storage tank D=28m,H=28m




API650 EN14015

D

H

Potential

weight savings *

*Based on minimum allowable thicknesses for tank shell in accordance with specified design code.

Duplex – any value for smaller tanks?

2 November 2012 17

Benefits:

• Higher durability: wear, dent

(permanent deformation) resistance

• Cost efficient alloying (High N, low Ni)

for highest corrosion resistance

• High pressure tanks –

strength utilization possible

? Constraints:

• Limited strength utilization –

critical design criteria:

stiffness/buckling resistance

• Design codes: allowable design

stresses, minimum shell thickness

requirements

Fabrication of Duplex

2 November 2012 18

Welding

• Weldability of duplex is good

• Most welding methods can

be used

• Welding characteristic

deviates from austenitic steel

• Always use appropriate filler

metal and procedures

• Welding personnel must be

informed and qualified

according to the demands of

the application

Machining

• Duplex steels generally more

difficult to machine than

austenitic grades

• LDX 2101 has excellent

machinability!

Cold forming

• Higher strength of duplex

grades: Greater working forces

and spring-back during forming

• Somewhat lower ductility

(fracture elongation, A5):

Avoid sharp bend radii and

more demanding forming

techniques

Welding of Duplex

2 November 2012 19

Welding of duplex is different from welding

austenitics in terms of:

• Joint angle (larger opening for

duplex)

• Shielding gas/Purging gas

• Speed (lower for duplex)

• Filler recommendations

(overalloyed)

• Autogenous welding with TIG

• Heat input

When changing from austenitic to duplex

qualify the operators and the procedures.

2 November 2012 20

Contents






Case: Cost analysis of storage tank shell

2 November 2012 21

Tank height: 20 m

Tank diameter: 20 m

Volume: 6280 m3

Surface area: 1260 m2

Density of content: 1 g/ml

Temperature: 20C

Design code: API 650

Joint factor: 1

Maximum allowable design stress:

Find out more:

www.outokumpu.com

Products >>

Tools >>

4307 (304L)

Sd=145 MPa

LDX 2101®

Sd=260 MPa

A516-60 (S235)

Sd=147 MPa

A537-2 (S420)

Sd=234 MPa

http://www.outokumpu.com/

Basic shell design – Structural efficiency

2 November 2012 22

Basic shell design in accordance

with API 650:

• Minimum shell thickness:

• 15 ≤ D ≤ 30 m min. td = 6 mm

• Plate width: 2000 mm

(10 shell courses H = 20 m)

• Corrosion allowance,

CA = 1.5 mm added to the

carbon steels

6.0

6.0

6.0

6.0

6.5

7.9

9.2

10.6

11.9

13.3

304L

82.7 mt

LDX 2101®

61.6 mt

S235

97.0 mt

S420

78.6 mt

-22%

+5%

+23%

Ref.

mm mm mm mm

7.5

7.5

7.5

7.5

8.0

9.3

10.6

12.0

13.3

14.6

7.5

7.5

7.5

7.5

7.5

7.5

7.5

8.1

8.9

9.8

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.7

7.4

D = 20 m

H =

20

m

td = + CA 4.9D(H-0.3)G

Sd

-26%

Ref.

Duplex improves both durability and

manufacturability

2 November 2012 23

Standards

Wider, longer and

thinner plates:

- Less joint preparation!

- Less welding!

- Shorter welding time!

14

1,28 kg/m*

4307/304L4307/304L

8

0,47 kg/m*

LDX2101®LDX2101®

~40% Thickness Reduction

~60% Weld Metal Reduction

*Filler metal consumption (FCAW) according to

The Avesta Welding Manual 2:ed 2005

Duplex grades not

difficult to weld,

but different:

- Follow welding

recommendations!

Improved fatigue, wear

and corrosion resistance:

= Longer service life!

Less corrosion – Less

maintenance compared

to coated carbon steel!

Smooth 2B

surface finish

suitable for the

food industry

available up to

6 mm!

Initial investment – ‘High’ cost level

2 November 2012 24

69

69

301

301

Internal surface treatment cost (USD/m2):

LDX 2101 304L A516-60 A537-2

22 22 180 180

External surface treatment cost (USD/m2):

LDX 2101 304L A516-60 A537-2

22 22 60 60

200

400

600

LDX 2101 304L A516-60 A537-2

x1000

USD

Material cost (USD/mt):

Based on average hot rolled coil prices per unit of

weight, 5-year-period (2005-2009).

LDX 2101 304L A516-60 A537-2

3200 3000 750 1000

Weight of plate materials (mt):

LDX 2101 304L A516-60 A537-2

61.6 -22% 82.7 +5% 97.0 +23% 78.6 ref.

117

175

207

141

Welding and assembly cost:

Based FCAW wire, typical welding and labor costs

for e.g. Northern Europe.

Wire consumption (kg):

LDX 2101 304L A516-60 A537-2

520 -37% 940 +13% 1210 +46% 830 ref.

Welding and assembly time (h)

LDX 2101 304L A516-60 A537-2

1400 -33% 2300 +10% 3000 +43% 2100 ref.

-27% -6% +14% Ref.

Higher strength – Weight savings –

Less welding – Less surface treatment:


199 249 91 81

Initial investment – ‘Low’ cost level

2 November 2012 25

22

22

100

100


LDX 2101 304L A516-60 A537-2

7 7 60 60


LDX 2101 304L A516-60 A537-2

7 7 20 20

100

200

300

LDX 2101 304L A516-60 A537-2

USD x1000

Material cost (USD/mt):

Based on average hot rolled coil prices per unit of

weight, 5-year-period (2005-2009).

LDX 2101 304L A516-60 A537-2

3200 3000 750 1000

Weight of plate materials (mt):

LDX 2101 304L A516-60 A537-2

61.6 -22% 82.7 +5% 97.0 +23% 78.6 ref.

33

43

43

29

Welding and assembly cost:

Based FCAW wire, typical welding and labor costs

for e.g. China, South-East Asia.

Wire consumption (kg):

LDX 2101 304L A516-60 A537-2

520 -37% 940 +13% 1210 +46% 830 ref.

Welding and assembly time (h)

LDX 2101 304L A516-60 A537-2

1400 -33% 2300 +10% 3000 +43% 2100 ref.

+20% +49% +11% Ref.

Higher strength – Weight savings –

Less welding – Less surface treatment:


199 249 91 81

Life cycle cost – Maintenance cost

2 November 2012 26

113

Maintenance cost

Cost analysis data:

Real interest rate: 4%

Life cycle duration: 30 yrs.

Complete recoating after 10 and 20 yrs.


LDX 2101 304L A537-2

- - 60


LDX 2101 4307(304L) S235 S420

- - 20

LDX 2101 304L A537-2

253 314 211

100

200

300

400

X1000

USD Initial investment cost (x1000 USD) LDX 2101 304L A537-2

253 +20% 314 +49% 211 ref. -22% -12% -18% Ref.

Note: Lost production time and

its cost at maintenance stop, as well as

final scrap value, are additional

favorable factors for stainless steel to

consider in the life cycle cost analysis.

Life cycle thinking with Duplex

2 November 2012 27

A sustainable product:

• Scrap-based production

• 100% recyclable

• Low level of metal ion release into the

environment

• High durability, longer lifetime – less

maintenance

• No need for environmentally harmful

protective coatings

• Avoid unsafe maintenance work

• Using Duplex’s strength to reduce

weight: Lower energy consumption,

lower CO2 emission levels.

2 November 2012 28

Contents






2 November 2012 28

Successful tank solutions in Duplex

2 November 2012 29

600

550

500

450

400

350

300

250

200

150

Du

ple

xA

us

ten

tic

43074404

4436

4438

4439

904L

254 SMO

4565

LDX 2101®

2304

2205

2507

LDX 2404®

Corrosion Resistance, CPT typical

Str

en

gth

, R

p0.2

[M

Pa

]

Hot coilMining and Minerals:

254 SMO in mix and collection

tanks for copper processing, Chile

Chemical industry:

2205 in phosphoric

acid tank, Sweden

Chemical industry:

2304 in acetic acid tank, Spain Mining and Minerals:

2507 in tanks for zinc processing, Spain Food industry:

LDX 2101 in tank farm for

edible oils, The Netherlands

Successful tank solutions in LDX 2101®

2 November 2012 30

Waste water treatment tank, Poland

Pulp and Paper liquor tank, Finland Palm oil tank farm, The Netherlands Corn silos, Hungary

Fabrication of storage tanks for honey

and edible oils etc., Spain

Wine tank park, Spain

Tank transportation, The Netherlands

Superior cost efficiency provided

with LDX 2101® for tank applications

in a variety of industries

New tank solutions with LDX 2404®

2 November 2012 31

Tank Specification:

Height = 20 m

Diameter = 22 m

Content density = 1,0 kg/dm3

Temperature = 20°C

Design code = API 650

Joint efficiency = 0,85

Allowable design stress:

• 4404 (316L) = 145 MPa

• 2205 (S32205) = 262 MPa

• LDX 2404® (S82441) = 296* MPa

* Not yet included in API 650 Appendix X.

The design stress shall be 0.4Rm.

Potential weight

saving as a substitute for 4404 :

~40%

20

18

16

14

12

10

8

6

4

2

[m]

Required thickness

Duplex LDX 2404®

72 tons

Required thickness

Duplex 2205

75 tons

Required thickness

Austenitic 4404

117 tons

Cr% Ni% Mo% Mn% N%

24 3.6 1.6 3.0 0.27

Our customers…

• Were enthusiastic about the potential of

duplex as a construction material

• Required corrosion resistance beyond

316

• Were not entirely satisfied with the

mechanical strength of 2304

• Could not fully benefit from the alloy

content of 2205

... were the starting point for LDX 2404®

2 November 2012 32

Contents






2 November 2012 32

2 November 2012 33

Conclusions: Cost-efficient and

sustainable solutions in Duplex

2 November 2012 33

• Enhanced Structural Efficiency due to higher allowable design strength –

No corrosion allowance

– Weight savings!

• Enhanced Durability due to higher corrosion and mechanical

resistance – Less maintenance – Less lost

production time – less environmental impact

– Longer and safer service life!

• Enhanced Manufacturability with good weldability and thinner gauges –

Less joint preparation and less welding

– Shorter fabrication time!

• Improved Cost Efficiency

and Sustainability!

Thank You!

www.outokumpu.com

Documents

Cost-Efficient and Sustainable Solutions With Duplex Nov 2012